Improved Effectiveness of Corrosion

Prevention and Control Systems for

Hydraulic Steel Structures

Thomas Carlson
Materials Engineer
USACE – Champaign, IL
Model Validation

21 June 2016

4th Biennial TRB-CMTS Research and

Development Conference, Washington D.C.
 Project Team

 ERDC-CERL
 Michael McInerney – Project Manager and Electronics Research Engineer
 Charles Marsh – Materials Engineer
 Vincent Hock (USACE RAO) – Metallurgist and NACE Fellow
 Jonathan Trovillion – Materials Engineer
 Matthew Brenner – Physicist
 Matthew Ziemann – Research Assistant
 Jason Selling – Research Assistant

 USACE Mobile District

 Anthony Perkins
 Greg N. Hall
 James Curry

 USBR
 Jessica Torrey

2
 Project Objectives

Structural Health
Condition Assessment Monitoring (SHM) System

1. A better understanding of cathodic protection and coatings, and their interaction.

2. Development of integrated CPC monitoring system with predictive capability.
3. Holistic approach will provide an input to overall SHM system.

Big Payoffs! 3
 What is CPC?

Corrosion Prevention and Control

Material Selection Cathodic Protection Coatings

1. Steel 1. Impressed Current 1. Coal Tar Epoxy

2. Stainless Steel 2. Sacrificial Anode 2. Epoxy
3. Polymer 3. Vinyl
4. Etc. 4. Urethane

4
 “Why Do We Care?”
Economic
-565 million tons of freight
valued at $214 billion (2012)
Cost
-$93,765,000 spent on corrosion
M&R in FY15 (USACE)
-Reduced O&M costs
Water Resources Infrastructure
-Corps Navigation Mission:
Provide safe, reliable, efficient,
effective and environmentally
sustainable waterborne
transportation systems for movement
of commerce, national security needs,
and recreation.
-Coastal Navigation
Maintain
-Inland Navigation (12,000 National
miles of navigable waterways
Assets
that touch 38 states) 5
 Project Overview
Structural
Health
Monitoring
System

90°
90°

45°
45°

Other Inputs

Data
Laboratory Products &
Field Survey Modeling Acquisition
Research Guidance
& Analysis
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 Field survey shows every square inch of the
structure is not protected from corrosion.

Pintle socket during dewatering Weld corrosion

Corrosion at Claiborne Lock due to inadequate CPC systems

Coating failure Flame cut drain holes

Corrosion around socket bolts
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 Laboratory Tests on Bare Steel Plates
Purpose: Use simple geometry in the lab to validate the modelling results.

“T” Plate Half Pipe

Measurements taken using half-cell probe:
-Native Potential
-Instant On
-Instant Off Potential (IOP) 8
 Bare Steel “T” Plate Schematic

4 separate impressed current anode locations: P1, P2, P3, P4.

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 Native Potential of Bare Steel “T” Plate
Tip of Half-Cell
Average native
potential of
720mV.

1
2
3
4

-Steel plate
showing general
-Measurements taken after native potential stabilized.
corrosion and
-Cathodic protection is not active.
location of half-
cell probe inside
280 gallon tank. 10
 “On” Potential of Bare Steel “T” Plate
Anode at 90 degrees (P1, P2). Anode at 45 degrees (P3, P4).

-Same half-cell
-DC potential was applied measurement locations
by mixed metal oxide -4 different anode
anode with constant locations (P1, P2, P3, P4)
driving voltage of 20 VDC.

11
 Polarization of Bare Steel “T” Plate

Anode at 90 degrees (P1, P2). Anode at 45 degrees (P3, P4).

NACE
100mV
Criteria

Reduced Polarization = Instant Off Potential – Native Potential Reduced

polarization polarization
region region
Results:
-Anode placement quantitatively shows an influence on the resulting surface
polarization distribution.
-According to the 100 mV DC polarization criteria, it is shown that some
12
locations are not protected.
 Comparison between experimental
measurements and model for “T” plate
Anode at 90 degrees (P1, P2). Anode at 45 degrees (P3, P4).

NACE
850mV
Criteria

Measurements
Model

Same Reduced Polarization Regions

Models generated using ANSYS Maxwell electromagnetic field simulation software. 13
 Comparison between experimental
measurements and model for “half-pipe” plate
IOP average (V) IOP average (V)
Anode at 90° Anode at 45°
NACE 1.15
1.05
0.85
850mV 0.95
0.75
0.65 Criteria
0.55
0.45
0.35
0.25 0.15
0.05 -0.05
-0.15 -0.25
-40 -20 0 20 40 -40 -30 -20 -10 0 10 20 30 40

Reduced Measurements Reduced

polarization Model polarization
regions regions

Same Reduced Polarization Regions

Models generated using ANSYS Maxwell electromagnetic field simulation software. 14

 Research Takeaway

 Effective application of cathodic protection is dependent on

 Anode placement
 Geometric complexity

 May also require changes to structure geometry

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 Data Acquisition & Analysis

Sensor

Gate structure

 A state of the art sensor with built-in coupons will measure native potential
and CP current density on a gate structure.
 Working with a commercial firm to develop a sensor which will measure
the CP effectiveness and coating degradation simultaneously
 A new application for lock gates.
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 Field Demonstration at
Mobile District:
Selden Lock and Dam
Selden Lock and Dam
on the Black Warrior
River

Installation on upper
gates while lower gates
are replaced.
Sensor located between anodes and below water level.

-Using rugged test probes, the field site will provide opportunity for long term
data acquisition and analysis of CP system performance.
-Will be the first time in many years a sensor will be installed on a lock gate to
monitor rectifier voltages/currents, and anode currents.
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 Field Demonstration System Schematic
Structural Health
Monitoring System

Data Other Inputs

- +
Gate
V

Anode Half Cell

Rectifier

- +
Current
Interrupter

One part of the holistic approach to Structural Health Monitoring of HSS. 18

 Products & Guidance
Journal article: “Combined Structure
Geometry and Anode Placement Effects
on Cathodic Protection Effectiveness”

• Inspection procedures for both CP protected

components and non-CP protected
components
• System specifications
• Recommended updates to Corps of
Engineers guidance documents such as EM
1110-2-2704
• Guidance for training

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 Conclusions
 Experiment and model provide insight into reduced
polarization regions which influence the
effectiveness of CP systems on complex structures.
 Field site data acquisition will confirm the presence
of adequate or inadequate CP on a real gate with
impress current CP.
 Updates to current guidance documents as well as
other research results will be published.
 Improved effectiveness of CPC systems on hydraulic
steel structures will help ensure that every square
inch of the structure is cathodically protected.

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